Structured material having apertures and method of producing the same

Abstract

A method for producing an apertured structured material for accommodating passage of fluids, particularly high viscosity fluids, through the apertured structured material. In one embodiment, the apertured structured material is a composite material formed by differential shrinkage of a shrinkable second layer, for example an ethylene-propylene copolymer, which is laminated to a first layer, for example a polypropylene polymer. During the differential shrinkage process, a plurality of slits which are formed in the second layer open to form uniformly-shaped apertures. In another embodiment, an apertured structured heterogenous material is made of a heterogeneous mixture of at least two homogeneous fiber sets or components having different shrinkage extents.

Description

BACKGROUND OF THE INVENTION[0001]1. Field of the Invention[0002]This invention relates to a method for producing an apertured structured material, for example a cover material or topsheet for personal care absorbent articles including diapers, feminine pads, incontinence garments, training pants, wound care products, and the like. The apertured structured material according to this invention provides a structure for accommodating passage of fluids, particularly high viscosity fluids such as menses, runny bowel movements, wound exudate and blood, therethrough.[0003]2. Description of Related Art[0004]Personal care absorbent articles such as sanitary napkins, disposable diapers, incontinent-care pads and the like are widely used, and much effort has been made to improve the effectiveness and functionalities of these articles. Conventional cover materials used in personal care absorbent articles do not provide for high viscosity fluids, for example menses, runny bowel movements, wound e...

AI Technical Summary

Benefits of technology

[0008]Materials suitable as a cover material or intake liner for feminine care products must quickly and efficiently handle menses. Menses has an average viscosity of approximately 10 cP. This is a slightly higher viscosity than the viscosity of water, which is about 1.0 cP. The suitable cover material should have a fast intake rate for high viscosity fluids, prevent menses from flowing back to the surface (reduce rewet), and allow only minimal staining. An ideal cover material may have the performance of a film (clean and dry) with the clothlike feel of spunbond.

[0009]Materials suitable for use as a cover material or intake liner for infant care, including diapers and training pants, must quickly and efficiently handle runny bowel movements without compromising the management of other fluids such as urine. A runny bowel movement has an average viscosity of about 25 Poise and a range of about 0.1 Poise to about 110 Poise. Approximately 87% of a runny bowel movement is water and the remaining 13% is composed of particles. The particles range in size from about 5.0 microns to about 900 microns with an average size of about 100 microns. Desirably, the cover material has a pore radius of greater than about 200 microns, more desirably greater than about 600 microns, to pass bowel movement particles through the cover material. It is also desirable to enhance pore size and pore volume to increase web permeability, thereby increasing the fluid intake rate. The cover material should also have a single point acquisition (direct intake and localization of runny bowel movements), high z-directional flow, rapid dewatering, and surface flow resistance.

[0010]The high viscosity fluid needs for professional health care, including bandages and the like, are slightly different than those for feminine care and infant care. The main priority for the development of fenestration products is to produce cost-effective alternatives for the current foam pads. The fenestration products should have a cover material with a high coefficient of friction to prevent the surgical tools from slipping on the fenestration reinforcement, and an ability to absorb wound exudates and other surgical fluids.

[0011]Accordingly, it is one object of this invention to provide a process for making an apertured structured material for use as a cover material in a personal care absorbent article for managing high viscosity fluids, for example menses, runny bowel movements, wound exudates and blood, without compromising the management of other fluids, for example urine.

[0012]It is another object of this invention to provide a process for making an apertured structured material for a personal care absorbent article which is soft and comfortable, absorbent, clean and dry.

[0013]It is another object of this invention to provide a process for producing an apertured structured material which has fluid intake and rewet properties similar to or better than more expensive model materials.

Problems solved by technology

Conventional cover materials used in personal care absorbent articles do not provide for high viscosity fluids, for example menses, runny bowel movements, wound exudate and blood.

As a result, the conventional cover materials used in personal care absorbent articles leak and contribute to poor skin health.

However, these conventional liners do not provide for particle intake.

As a result, the particles contained within the high viscosity fluids separate during absorption of the water and tend to remain on the surface of the liner to produce undesired interactions with the wearer's skin.

However, these materials are costly to manufacture.

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